Device for packaging and cooking kernels of corn for making popcorn

ABSTRACT

A device for packaging and cooking popcorn includes in the lower part an essentially rigid base, and in the upper part a compensating zone that can occupy a first folded position in which it forms a cover for the base and delimits a restricted volume, and a second unfolded position in which it forms a tube and delimits a larger volume suited to that of the cooked popcorn. The device is produced from a complex material that includes a layer made of cardboard-type material to ensure the rigidity and a layer that is made of flexible and airtight plastic that is placed on the surface oriented toward the inside of the device. The device includes a window at least at the level of a wall of the compensating zone, whereby the complex material does not have a layer that is made of cardboard-type material to the right of the window.

This invention relates to a device for packaging and cooking in particular kernels of corn for making popcorn. More generally, this device is suitable for all the foods whose cooking results in a significant increase in volume.

According to the document WO2004/032633, such a device is known that comprises a first container with—in the lower part—an essentially rigid base on top of which is a compensating zone that can occupy a first folded position in which it forms the cover of the base so as to delimit a restricted volume that is suited to kernels of corn and a second unfolded position in which it forms a tube that extends the lateral walls of the base so as to delimit a larger volume suited to the volume of the popcorn after cooking.

The compensating zone comprises four lateral walls in the extension of the lateral walls from the base, two opposite walls that are called retractable walls, comprising a median folding line that is parallel to the bottom at mid-height, and the other two opposite walls—called stiffening walls—comprising a first median folding line that is parallel to the bottom at mid-height and second cross-shaped folding lines.

The tube generally has a flared shape. To achieve the unfolding of the compensating zone, it is necessary to provide a cut—at the level of the stiffening walls at the median folding line—for allowing the unfolding of the compensating zone. Actually, it is not possible to pass from the folded state to the unfolded state without this cut.

To close the tube, the compensating zone comprises flaps in the upper part to make it possible to close the device.

According to this document, whereby the tube is not airtight due to the presence of cuts at the stiffening walls, the kernels of corn are placed in a small container and are covered by a film that is bonded with a thermosetting glue against the lateral walls of the small container, whereby the latter is placed in the first container whose restricted volume is suited to the small container.

During cooking, the kernels of corn pop and turn into popcorn. At the same time, the film disengages from the small container to release the popcorn.

Cooking is complete when all the kernels have popped and no more kernels can be heard popping.

Even if this packaging device is satisfactory, it can be improved.

According to a first drawback, it is necessary to provide two separate elements, namely a first container that forms a tube and a second container that forms a small container. For each, these two elements require a mechanical device for their production. Furthermore, during the production process, it is necessary to place the small container in the tube. This phase has to be performed by hand or requires complex mechanization.

According to another drawback, the film of the small container is mixed with popcorn at the end of the cooking, which is not very appetizing. Furthermore, this hot film can produce burns if the user takes it out too early or without protecting himself.

According to another drawback, the flexible film can bend during bonding with the small container so that the junction between the film and the small container is not perfect and can leave small gaps. These gaps can create leaks of fatty substances toward the outside that then saturate the first container or leaks of air toward the inside of the small container that then oxidize the foods, and the effect of this is a shortening of the expiration date for consumption.

Finally, according to a last drawback, whereby the microwave ovens that are used for cooking have disparate powers, it is difficult to determine a cooking time. For the moment, the user can only trust his ear and stop the cooking when he no longer hears the kernels popping. Also, there is no means for indicating, in a practical manner, the end of the cooking.

Also, this invention aims to remedy the drawbacks of the prior art by proposing a device for packaging and cooking in particular for the kernels of corn, airtight, and making it possible to use it with no danger.

To this end, the invention has as its object a device for packaging and cooking that is suited to popcorn and that comprises an essentially rigid base in the lower part and a compensating zone, which can occupy a first folded position in which it forms a cover for the base so as to delimit a restricted volume and a second unfolded position in which it forms a tube so as to delimit a larger volume that is suited to the volume of the popcorn after cooking, in the upper part, characterized in that it is produced from a complex material that comprises a layer that is made of cardboard-type material to ensure the rigidity and a layer of flexible and airtight plastic material that is placed on the surface oriented toward the inside of the device, and in that it comprises a window at least at the level of a wall of the compensating zone, whereby the complex material does not have a layer that is made of cardboard-type material to the right of said at least one window.

This invention is described in detail opposite the accompanying drawings that show a preferred but non-limiting embodiment, whereby the figures correspond to

FIG. 1, a view of the device for the display and cooking of kernels of corn according to this invention, in the unfolded position,

FIG. 2, a view of this same device in folded position,

FIG. 3, a view of the upper part of the device after cooking,

FIG. 4, a section illustrating a sheet in which a panel is cut out to obtain the device according to the invention,

FIG. 5, a view illustrating a first variant of a panel to obtain the device of the invention,

FIG. 6, a view illustrating another variant of a panel to obtain the device of the invention, and

FIG. 7, a view illustrating another variant of a panel to obtain the device of the invention.

In FIGS. 1 and 2, a device for the packaging and cooking of in particular kernels of corn for making popcorn is shown at 10. More generally, this device is suited for all the foods whose cooking leads to a significant increase in volume. By way of example, its use could be considered for cooking puff-type biscuits.

This device 10 comprises a container 12 with a base 14 and a compensating zone 16 that can occupy a first folded position in which it forms the cover of the base so as to delimit a restricted volume that is suited to kernels of corn and a second unfolded position in which it forms a tube that extends the lateral walls of the base so as to delimit a larger volume that is suited to the volume of the popcorn after cooking.

The base has a rigid rectangular or square shape over a height on the order of 1 to 2 centimeters to clarify the ideas. The base comprises a bottom 18, which is also the bottom of the container 12, and four essentially rigid lateral walls 20.

The compensating zone 16 is folded in FIG. 2, but with an unfolding initiator so as to be able to distinguish the different parts. In reality, the height of the unit seems to be essentially the same as that of the height of the base.

This compensating zone 16 comprises folds, respectively located on the walls opposite said first walls 22 and second walls 24.

The first walls 22 each comprise a fold 26 that is called a median fold, whereby this fold is essentially in the middle of each of the surfaces of the first walls and parallel to the base.

The second walls 24 each comprise several folds, a first fold 28 in the continuity of the folds 26, placed in the middle of each of the surfaces of the second walls and parallel to the base and so-called diagonal folds 30 along the diagonals of the surfaces of the second walls.

When the container 12 is in the folded state, the first walls are folded in two along the folding lines 26 for each first wall 22, whereby the two parts that are placed on both sides of the folding line 26 are flattened against one another. The second walls 24 deform along the folding lines 28 and 30 so as to form an accordion, whereby for each second wall, the intersection of the folding lines 30 moves toward the inside of the container.

Advantageously, the container 12 has a shape that is flared upward to obtain an upside-down truncated pyramid.

According to the invention, the container 12 is made of a cardboard-type material to ensure the rigidity with a window 32—at the level of at least a second wall 24 and preferably on each second wall 24—to the right of the zone of intersection of the diagonal folds 30, whereby said window 32 is sealed by a flexible and airtight material. According to a characteristic of the invention, the container is obtained from a panel 34 that is made of a complex material that comprises a layer 36 of cardboard-type material to ensure the coated rigidity of a layer 38 that is made of flexible and airtight plastic, whereby the complex does not have a layer 36 that is made of cardboard-type material to the right of the windows 32 but only a layer 38 that is made of flexible and airtight plastic as illustrated in FIG. 4. The plastic layer 38 is oriented toward the inside of the container, and the cardboard-type layer 36 is oriented toward the outside of the container. In addition, the layers 36 and 38 are connected to one another permanently so as not to disengage during cooking.

This solution has the following advantages:

It makes it possible to make the container 12 airtight, whereby the inside surfaces of the container are coated by a plastic layer. Thus, it is possible not to use a small container as indicated in the prior art. Thus, only a single container is produced.

The presence of only the plastic layer 38 at the windows 32 makes it possible to allow the passage from one state to the next, in particular from the folded state to the unfolded state.

By way of indication, the window 32 is centered on the second wall and at a height on the order of 50 mm and a width on the order of 115 mm.

According to a preferred embodiment, the plastic layer 38 is transparent so as to be able to visualize the kernels of corn during the cooking.

The plastic layer 38 can be made of PET or polyethylene terephthalate.

According to an embodiment, the folding lines 26, 28, and 30 are created by making grooves in the panel that is made of a complex material or by continuous or intermittent cutting and/or prescoring of only the layer 36 that is made of cardboard-type material.

The container 12 optionally can comprise unfolding means comprising two tabs, one per first surface 22, whereby each tube is advantageously T-shaped, whereby the transversal branch is glued directly to the outside surfaces of the first walls 22.

According to an embodiment, the container 12 comprises opening/closing means 40. These means 40 comprise two flaps 42 that can be folded back, whereby the flaps are connected by a folding line 44 to two opposite lateral walls 22 or 24. In a closed position, these flaps 42 are connected to one another and to the compensating zone 16 so as to obtain an airtight chamber, whereby the bonds are thermosetting so as to break when the temperature exceeds a certain threshold during the cooking.

According to an embodiment, the free ends of the flaps 42 can comprise folds 46 whose inside surfaces, coated by a plastic layer 38, are bonded in a thermosetting manner, whereby the folds 46 that are glued against one another are then folded back against the outside surface of one of the flaps 42.

The lateral edges of the flaps 42 can be extended by folds 48 that are flattened against the outside surfaces of the corresponding lateral walls of the compensating zone 16 so as to achieve an airtight closing. According to an embodiment, the opening/closing means 40 in addition comprise first flaps 42, and second flaps 50 that are connected via folding lines 52 to the opposite lateral walls 24 or 22 to which the first flaps 42 are not connected. The folds 48 that comprise only the plastic layer 38 are bonded in a thermosetting manner against the inside surfaces of the second flaps 50 that are coated by a plastic layer 38. The second flaps 50 are then folded back against the outside surfaces of the first flaps 42 as illustrated in FIGS. 1 and 2.

According to the cases, the second flaps 50 have a more or less significant height. According to a variant, the flaps 42 and 50 have a suitable height such that when they are in a completely open position, the free ends of said flaps are located close to the upper surface of the chamber of the oven so as to prevent the popcorn from jumping outside of the first container 12.

According to an embodiment, the first flaps 42 are connected to one another by a tab 54 that prevents the complete opening of said flaps 42. This tab 54 comprises a prescoring 56 so as to break said tab 54 and to allow the complete opening of the flaps 42.

As a variant, the flaps 42 and 50 can be detached from the remainder of the container.

The operation of the means 20 for opening and closing is as follows:

In closed position, the flaps 42 and 50 are folded back as illustrated in FIGS. 1 and 2.

During cooking, the bonds open between the flaps 42, on the one hand, and between the flaps 42 and 50. During cooking, the volume of the popcorn tends to increase, causing the opening of the first flaps 42. This opening of the first flaps 42 is slowed down, whereby the second flaps 50 have a tendency to remain in folded-back position and to prevent the opening of the first flaps 42. This opening movement can also be controlled by the tab 54 that prevents the complete opening of said first flaps 42 so as to keep the popcorn inside the container 12, as illustrated in FIG. 3.

It is possible to adjust the rising height based on, in particular, the length of the tab 54. The rising of the flaps can be used to indicate the end of the cooking.

The bottom 18 of the container can be carried out in the same manner as the opening/closing means 40, whereby the bonds are not thermosetting, but rather permanent, in the case of the bottom.

According to a preferred embodiment that is illustrated in FIGS. 5 and 6, the bottom 18 comprises four flaps 58 and 58′, each connected to a lateral wall 20 of the base 14, and two flaps 58′ that are arranged facing one another and that have folding lines that make it possible to make accordions.

According to this embodiment, the flaps 58 and 58′ are connected two by two by folding lines 60 and comprise folds 62 at their free ends.

The flaps 58′ each comprise a V-shaped folding line 64 whose V point is located in median position at the corresponding folding line that connects said flaps 58′ to the folds 62 and whose ends of the V-shaped branches are connected to the angles of the bottom 18. According to this embodiment, the flaps 58′ are located above the flaps 58 inside the container.

To keep the bottom in a closed position in an airtight and permanent manner, the interior surfaces of the folds 62 that are connected to the flaps 58 are glued against one another, then the thus glued folds are folded back against the outside surface of one of the flaps 58.

To bond or join the elements, it is possible to use a related element such as a thermosetting bond or not, as required, or no related element, whereby the plastic surfaces of the complex are heated, then flattened against one another in the connecting zones.

To make a permanent joint or a thermosetting joint that breaks during cooking, the temperature elevation is adjusted during the joining. By way of example, for a complex with a surface made of PET or polyethylene terephthalate, an elevation that is greater than or equal to approximately 270° C. is produced to achieve a non-reversible joint and a temperature elevation on the order of 180° C. to achieve a reversible joint and to achieve a thermosetting bond.

At certain zones, the complex that is used to form the container can comprise a layer 66 that is made of material that absorbs the electromagnetic waves.

According to an embodiment that is illustrated in FIG. 5, the lateral walls 20 of the base and optionally the lower part of the walls 22 and 24 of the compensating zone comprise a layer 66 that is made of absorbent material, indicated by dashes.

According to another embodiment that is illustrated in FIG. 6, only certain portions of the flaps 58 and 58′, in particular the angular portions that are visible from the inside of the container at the inside face of the bottom 18, comprise a layer 66 that is made of absorbent material, indicated by dashes.

To form a tube, the walls 20 and 22 are connected two by two via folding lines, and one of the lateral walls comprises a fold 68 that makes it possible to connect to another lateral wall.

According to the invention, a device that comprises a single element, namely an airtight container that does not require the presence of a second container or a detachable film that is able to cause burns, is obtained.

According to the invention, in a first step, a tube is produced by ensuring a permanent bond between the fold 68 and the corresponding lateral wall.

The bottom is then formed also by producing permanent-type bonds.

The compensating zone is then in unfolded position.

Next, the container 12 is filled with kernels of corn. The dimensions of the base are suited to the volume of the corn.

The container is then closed using thermosetting-type bonds.

The container 12 is then deformed so as to place the compensating zone in folded position.

The packaging devices are then packaged in the folded state in a plastic film that keeps them in this state. The devices can be stored in the unit or by group.

To cook the popcorn, the user takes the device from its packaging then inserts it into a microwave oven. The cooking of the first kernels leads to an increase in pressure inside the device than then unfolds, the latter being closed in an airtight manner. During cooking, the opening/closing means 40 open up. At the end of the cooking, the opening/closing means rise slightly to indicate the end of the cooking. It is enough to remove the device from the oven and to dig into the popcorn without needing to remove a burning and unappetizing film.

FIG. 7 shows a panel 100 that makes it possible to obtain a packaging device according to the invention.

The references that are common to the preceding variants are increased by 100.

This panel comprises a bottom 118 of a central part, with an essentially square shape, with lateral walls 120 at each side that form the essentially rigid base 112. The first and second walls 122 and 124 are connected to the lateral walls 120 via folding lines. Contrary to the preceding panels, the bottom is made of a single support and all the walls 122 and 124 have a common side with said bottom, whereby the latter are placed in the manner of petals.

As above, the first and second walls 122 and 124 comprise folding lines 126, 128, and 130 as well as windows 132. To form the packaging device, the lateral walls 120 and the first and second walls 122 and 124 are straightened so as to delimit a container.

The device that is obtained preferably comprises the same opening/closing means 140 as described above. Thus, the first and second flaps 142 and 150 are provided at the upper ends of the first and second walls 122 and 124. Folds 146 are also provided at flaps 142 to ensure the bond between said flaps. Likewise, folds 148 are also provided to ensure the bond between the first flaps 142 and the second flaps 150. As above, these bonds are preferably thermosetting.

A tab 154 with a prescoring 156 can be provided to connect the flaps 142.

In addition, the device can comprise unfolding means as described above.

According to this embodiment, to ensure the bond between the first and second walls 122 and 124, accordions 170 are provided to connect them two by two. Each accordion 170 comprises two triangular parts, each triangular part having a first common side with an edge of a wall 122 or 124 and a second common side with the other triangular part of the same accordion 170. These accordions 170 extend from the bottom 118, over the entire height of the walls 122 and 124.

This configuration makes it possible to obtain a container with sealing that is reinforced to the extent that there is no seam in the lower part. In addition, according to this embodiment, the necessary seams are of a single type, namely thermosetting, making it possible to use a simple complex with a single plastic film.

According to this embodiment, the accordions 170 are folded inside the container, whereby the outside surfaces of the triangular parts are flattened against one another. Next, the thus folded accordions are folded back against the first walls 122. Thus, two accordions 170 are folded back against each first wall 122. To obtain the compensating zone, the accordions 170 comprise folding lines 172 that are placed at folding lines 126 when the accordions 170 are folded back against the first walls 122.

To ensure that the accordions 170 are held against the walls 122, for each pair of accordions 170 flattened against the same wall 122, bonding means are provided between the accordions 170 of the same pair to keep them flattened. For each pair of accordions 170 that are flattened against the same wall 122, a first accordion 170 comprises a fold 174 that can ensure the connection between the two accordions by being folded back, whereby the upper part of the second accordion 170 that does not bear the fold 174 is inserted between said fold 174 and the first accordion 170. However, the invention is not limited to this embodiment of the bonding means between accordions.

To facilitate the folding, the folding lines can be obtained by a cut of the layer that is made of cardboard-type material of the complex alone, whereby the plastic layer ensures the sealing and the bond between the various portions of the layer that is made of cardboard-type material. 

1. Device for packaging and cooking that is suited to popcorn and that comprises—in the lower part—an essentially rigid base (14) and—in the upper part—a compensating zone (16) that can occupy a first folded position in which it forms a cover for the base so as to delimit a restricted volume and a second unfolded position in which it forms a tube so as to delimit a larger volume that is suited to the volume of the popcorn after cooking, characterized in that it is produced from a complex material that comprises a layer (36) that is made of cardboard-type material to ensure the rigidity and a layer (38) that is made of airtight and flexible plastic that is placed on the surface oriented toward the inside of the device, and in that it comprises a window (32) at least at the level of a wall of the compensating zone (16), whereby the complex material does not have a layer (36) that is made of cardboard-type material to the right of the window (32).
 2. Device for packaging and cooking according to claim 1, wherein the compensating zone (16) comprises first opposite walls (22) that each comprise a median folding line (26) and second walls (24) each comprising a median folding line (28) and diagonal folding lines (30), and wherein each second wall (24) comprises a window (32) at the intersection of the diagonal folding lines (30), whereby the complex material does not have a layer (36) that is made of cardboard-type material to the right of the window (32).
 3. Device for packaging and cooking according to claim 1, wherein the plastic layer (38) is transparent.
 4. Device for packaging and cooking according to claim 1, wherein it comprises means (40) for opening and closing that comprise two flaps (42) and bonds between said flaps (42) and between said flaps (42) and the compensating zone (16) of a thermosetting type so as to be broken when the temperature exceeds a certain threshold during cooking.
 5. Device for packaging and cooking according to claim 4, wherein the means (40) for opening and closing comprise first flaps (42) and second flaps (50) and wherein said first flaps comprise folds (48) at the lateral edges, whereby said folds that comprise only the plastic layer are able to be glued against the inside surfaces of the second flaps (50).
 6. Device for packaging and cooking according to claim 4, wherein the free ends of the first flaps (42) comprise folds (46) whose inside surfaces, coated by a plastic layer (38), are bonded in a thermosetting manner.
 7. Device for packaging and cooking according to claim 4, wherein it comprises a tab (56) that makes it possible to control the opening of the flaps (42).
 8. Device for packaging and cooking according to claim 1, wherein to form the bottom (18), it comprises four flaps (58, 58′) that are connected two by two by folding lines (60), whereby two opposite flaps (58′) comprise a V-shaped folding line so as to form an accordion fold.
 9. Device for packaging and cooking according to claim 1, wherein the complex material comprises a layer (66) that is made of a material that absorbs the electromagnetic waves at the level of at least certain zones.
 10. Device for packaging and cooking according to claim 2, wherein the plastic layer (38) is transparent.
 11. Device for packaging and cooking according to claim 2, wherein it comprises means (40) for opening and closing that comprise two flaps (42) and bonds between said flaps (42) and between said flaps (42) and the compensating zone (16) of a thermosetting type so as to be broken when the temperature exceeds a certain threshold during cooking.
 12. Device for packaging and cooking according to claim 3, wherein it comprises means (40) for opening and closing that comprise two flaps (42) and bonds between said flaps (42) and between said flaps (42) and the compensating zone (16) of a thermosetting type so as to be broken when the temperature exceeds a certain threshold during cooking.
 13. Device for packaging and cooking according to claim 5, wherein the free ends of the first flaps (42) comprise folds (46) whose inside surfaces, coated by a plastic layer (38), are bonded in a thermosetting manner.
 14. Device for packaging and cooking according to claim 5, wherein it comprises a tab (56) that makes it possible to control the opening of the flaps (42).
 15. Device for packaging and cooking according to claim 6, wherein it comprises a tab (56) that makes it possible to control the opening of the flaps (42).
 16. Device for packaging and cooking according to claim 2, wherein to form the bottom (18), it comprises four flaps (58, 58′) that are connected two by two by folding lines (60), whereby two opposite flaps (58′) comprise a V-shaped folding line so as to form an accordion fold.
 17. Device for packaging and cooking according to claim 2, wherein the complex material comprises a layer (66) that is made of a material that absorbs the electromagnetic waves at the level of at least certain zones. 